Concrete building element



S. LAKE- CONCRETE BUILDING ELEMENT Filed Aug. 20, 1924 3 Sheets-Shee t 1Nov.

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s. LAKE- CONCRETE BUILDING ELEMENT Filed Aug. 20, 1924 3 Sheets-Sheet 2Nov. 24,1925. 1,562,706

S. LAKE CONCRETE BUILDING ELEMENT Filed A112. 20, 1924 s Sheets-Sheet 5Patented Nov. 24, 1925.

UNITED STATES SIMON LAKE, OF MILFORD, CONNECTICUT.

CONCRETE BUILDING-ELEMENT.

Application filed August 20, 1924. Serial No. 733,208.

- To all whom it may concern:

Be it known that I, SIMON LAKE, a-citi- 'zen of the United States,residing at Milford, in the county of New Haven andState of Connecticut,have invented a certain new and useful Improvement in Concrete BuildingElements, of which the following isa full, clear, and ex/actdescription.

This invention relates to a concrete building element suitable for usein the construction of walls, floors and roofs of buildings,

and so designed and fabricated as to meet all of the requirements ofstrength, perma nence and adaptability incident to its several uses.

One object of the invention is to provide a'concrete building elementwhich will lend itself readily to quantity production and shipment, andwhich may be used as a substitute for other buildingelements ormaterials.

Another object is to provide a building element of such a nature that itmakes pos-] sible the constructionof buildings in a much shorter timethan has heretofore been possible, thus materially reducing the cost ofconstruction.

A further object is to provide a building element of such formation thata building constructed of same will be insulated against heat and cold,will be moisture and vermin proof, fire safe and sanitary.

The invention consists in aconcrete building. element composed, ineffect, of two slabs forming the faces of the element, and these slabsjoined together and held in spaced relation to each other bylongitudinal and transverse webs or spacing means, the webs and theslabsprovided with reinforcing and strengthening members tied togetherto form a reinforcing framework bonded in the concrete of the element,as I will proceed now to explain and finally claim.

In the accompanying drawings illustrating the invention, in the severalfi res of which like parts are similarly designated, Figure 1 is afragmentary perspective view illustrating the various members of thereinforcing framework. Fig. 2 is a longitudinal section of a finishedelement. Fig. 3 is a fragmentary transverse section taken on the line3-3 of Fig. 2. Fig. 4 is a fragmentary section similar to that of Fig.2, but

showing a modification. Fig. 5 is a section through the reinforcingframework taken shown mFig. 2. Fig. 7 is a fragmentary plan view of anelement such'as is shown in Fig. 4:. Figs. .8 and 9 are fragmentarysections illustrating the method and apparatus for forming the elements.Figs. 10 and 11 are top plan view-s of cores, such as shown in Fig. '9,for use in the manufacture of the elements. F ig. 12 is a section takenon the line 1212 of Fig. 10., Fig. 13 is a perspective view of a device,such as shown in Fig. 9, for supporting the cores during the operationof forming the elements.

My building elements may be made in a variety of shapes and izes, andthey may be provided with openings for doors and windows by theincorporation in them' of ment of rectangular form, without openings. i

The invention is best described by setting forth the method of itsproduction, and this method may be stated as follows I take a pluralityof transverse members or boards 1 rovided on their inner faces withgrooves 2 extending throughout their length and upon their outer faces,with similar grooves 3. These members 1 are arranged in pairs and aresuitably spaced apart by spacers 4 arranged adjacent to their ends,which spacers in addition to maintaining the members 1 in proper spacedrelation serve as a means for connecting them by nails, screws or thelike 4', which are driven through the members 1 and into the spacers 4.The pairs of mem- St I the building element to be formed and aremaintained in such spaced relation means of separator members 5 arrangedetween them and substantially midway of their length, as shown. As willbe seen, particularly lby reference to- Fig. 1, the members 1 are Sotherwise secured the edge pieces 7 provided with rabbets 8. After theseedge pieces have been secured in place, flat reinforcing bars bedofi attheir ends as at 6 and on these slabbed off portions are nailed or' beensecured in place, wire mesh 10 is laid over the whole exposed surface ofthe framework with its longitudinal edges resting in the rabbets 8 ofthe edge pieces 7, and is nailed or stapled to these edge pieces and tothe members 1. The whole framework is then bodily turned over and edgepieces 7', similar to the edge pieces 7 and provided with rabbets 8',are secured upon the slabbed 01f portions' 6' of the members 1. Thenlongitudinal reinforcing rods or compression members 11 are stapled orotherwise suitably secured to the members 1, and wire mesh 12 ispositioned over the whole exposed surface of the framework, with itslongitudinal edges engaging with the rabbets 8 of the edge pieces 7",and is secured to the framework in the same manner as is the wire mesh10. This structure comprises the foundation or main supporting andstrengthening framework for the building element.

Referring now to Figs. 8 and 9, a layer of concrete or cement plaster 13of suitable thickness and consistency isspread upon a pallet 14prQerably of hollow construction providing a space 15 in to which steamor other heating fluid may be introduced, for a purpose later explained,and then the whole framework just described. with the side carrying thebars 9,downward, is placed upon this layer of concrete 13 and is workedinto same until the wire mesh '10 and members 9 are embedded therein.Then a hoelike levelling tool 16, provided on its edges with pins 17 andwith a handle 18, is run into the-s aces between the pairs of members 1,wit its pins 17 finding bearings and guides in the grooves 3 of themembers 1 and the concrete in these spaces is screeded off to a uniformthickness and surface conformation. As will be seen, the members 1 areprovided with undercut grooves 19 on their upper and lower edges which,due to their dove-tail shape, form a retaining con-v nection or bondwith the concrete, thus anchoring the concrete to them in addition toits bond with the bars 9 and wire mesh 10.

After the molding operation has been carried this far, transversereinforcing rods 20 are inserted in the spaces 21, the spaces are filledwith concrete to approximately the level of the grooves 2, andinsulating members or strips 22 are then slid into the grooves 2 fromthe ends of the members 1 These insulating members are provided withappropriately positioned openings 23 and 24, and through these openingsand into the plastic concrete are forcedremforcing rods 25 and 26respectively, and through similar openings 27 are inserted reinforcingand tying members 28 which bond with the concrete below the insulatingmembers 22 and are hooked over the longitudinal rods 11. After thesevarious elements have been poing with additional concrete, the topportion or slab of the element may be formed as nextdescribed;

Boards or the like 29 having hinged to them cam. members 30 providedwith handles 31, as shown in detail in Fig. 13, are laid upon the lowerslab of the element, as shown in Fig. 9, but with the cam members 30turned down so as to lie flat u on the boards 29. Then the coresillustrate in Figs. 9, 10, 11 and 12 are slid into the spaces betweenadjacent pairs of members 1, and the handles 31 are turned to raise thecam members 30 to thereby elevate the cores to casting position, asshown in Fig. 9. With the cores in this position, concrete is spreadover the whole upper surface of the frame of the element, and is workedthrough the wire mesh 12, suflicient concrete being supplied to form asubstantial coatin above the mesh 12, as shown in Fig. 2, and 1sscreeded off to the desired uniform thickness, the cores arranged asdescribed forming a bedto receive the concrete thus applied.

It is during this operation that the filling of the spaces 21 betweenthe members 1 may be completed and the rods 20' inserted, ashereinbefore indicated, and. I prefer to 'follow this procedure.

This last operation completes the casting or molding of the element.

In order to quickly dry out the concrete to hasten its a uiring such aset as will permit the ban ing of the element without danger offracture, I prefer to artificially heat the entire concrete body, andthis I do by the introduction of steam into the space 15 of the pallet14 and into the interior of the cores.

By reference to Figs. 10 and 12, it will be seen that the cores are ofwaflie-like formation as regards their surface contour and comprise basemembers 32 to which are attached stamped or otherwise formed members 33providing between them a depression 34 whic when in casting position,lies beneath one of the rods 11, and when the concrete is poured uponthe core,

forms a rib 34', Figs. 2, 3 and 4, running suitably vides in addition tothe longitudinal rib 34' an intermediate. transverse l'lb upon the underside of the upper slab. of the element.

After the concrete ha's attained its initial ments may be of such sizethat a sing e element will suflioe for each wall thereof and for thefloors and roofs, orv it ma be necessary to use a number of the e ementsto construct a wall, floor or roof.

a wall, floor or roof, the edges of the element may be finished as shownin 7 by casting concrete upon its ends and e g'es, such concrete bondingwiththe reinforcmg elements which extend beyond the edges 0 thereinforcing framework.

Where a plurality of elements must be used, elements such as shown inFig. 6 may be used, wherein the reinforcing elements extend beyond theedges. In uniting adjacent elements of this last mentioned type asindicated in Fig. .5, the abutting ends of the bars 9 and rods 11 arewelded or otherwise united, and the wire mesh of adjacent elements islaced or otherwise joined, or merely overlapped, and'then the spacebetween the elements and including these interlocked and welded"reinforcing elements is filled with a strong grout which is screededoff into uniformity with the surfaces of the adjacent elements, to formin effect a continuous unbroken face. The above'refers rincipally to thejoining of the ends of the huilding elements, but itwill be apparentthat it may be necessary in structures of considerable size, orcontaining' a number of stories, to super ose one element edge'wise uponanother.-, hen my elements are to be usedinthis relationship, it may befound expedient to leave their edges unfinished,"so that air space willextend fromthe eenter gfone-element to the center of. the next adjacentelement, but if this is not desired, the-lends "of the cored openings,and" the spaces '21 between the members -1 may be'closed by boards orinsulating material 47; upon which wire mesh 48 may be nailed, andconcrete-applied there to to complete the edges of the member as 11shows a'modified'form of core'in in addition 'to-' the depression34;;there; ,is a transverse de ression; 35 which-fw1ththe depressiondi"divides the surface of the core into four raised portions 36 and pro--shown in Figs. 3, 6 and 7 at {19, and as in- "dicated. in Flg. 5, by thebroken lines.

By m construction, it will be seen that j'If-provi e. a concretebuilding element having a reinforcing framework adapted to absorblongitudinal and transverse strains,

and having reinforcing elements combined with the concrete fordistributing pressures exerted upon the building element. from above andbelow whether localized or even Fig. 3, between the separator members 5.When a single element only is needed an.

I produce, by my invention, a building element of very light weightrelative to its -with the reinforcing framework and bonded by 28-.ft. 5in. long by 3 in. thick, with a 2% in. airspace, thus making the upperand lower slabs only in. thick. Such a slab when only thirteen days oldwas found on ofiicial test to be capable of supporting a load of eightypounds per square foot without damage of any sort. 7

, Referring to Fig. 4, it will be seen that, if desired, the value ofthe dead air space as an insulator against transmission through theelement of heat, cold, moisture and sound may be enhanced by theaddition of an insulating partition member 66 which may be slid into thegrooves 3 and positioned thereby in spaced relation to the upper andlower slabs of the element, thus forming two dead I air spaces insulatedfrom each other by the member 66.

As hereinbefore indicated, when the element is used in substantiallyhorizontal position' for the construction of floors or roofs,

its reinforcing members. are capable of sustaining loads eitherlocalized or evenly distributed, and whet-her applied from above orbelow, and when used in vertical position, as in awall, will sustainloads applied from either side.

Moreover, itwill be seenth'at, due to the arrangement of the memberscomprisin the reinforcing framework proper, and o the reinforcing rods,bars, wire mesh and other elements applied, thereto and embedded in theconcrete of the slabs and webs, loads, no

matter how or where-applied upon the element, will be distributed andabsorbed throughout the whole element.

Various changes are contemplated as within the s )irit of the inventionand the scope of the following claims.

What I claim is 1. A concrete building element, comprising a pair ofsubstantially similar. slabs, longitudinal and transversewebs connecting"said slabs and maintaining them in predetermined spaced relation, areinforcing framework embedded in said slabs and deslabs, andreinforcing members embedded in said webs and interengaging withthereinforcement of said slabs.

3. A concrete building element, comprising a pair of similar slabs, websextending longitudinally and transversely thereof and serving to connectthem in spaced relation, insulating means incorporated-in said webs andserving to prevent transmission of heat, cold and moisture from one slabto the other, and reinforcing elements embedded in said webs and passingthrough said insulat ing means for tying the slabs together.

4. A concrete building element, comprising a pair of substantia lysimilar slabs, re-

- inforcing elements incorporated in each of said slabs, webs arrangedbetween and integral with said slabs'and serving to maintam same inspaced relation, and reinforcing elements embedded in said webs andinterlocking with the reinforcing elements of said slabs.-

.5. A concrete building element, com rising a pair ofsubstantiallysimilar sla s, a non-metallic framework embedded in saidslabs and having web-formin members, webs of concrete defined by saidmembers and connecting said slabs in s aced relation, insulating meansincorporate in said webs and ada ted to prevent transmission of heat,cold an moisture from one slab to the other through said webs, metallicreinforcing elements incorporated in each of said slabs, and

metallic reinforcing members embedded in 0 said webs and extendingthrough said insulating means and bonded in said slabs for connectingthe slabs together through said webs.

6. A concrete building element, compris ing a pair of substantiallsimilar slabs spaced apart to form dea air chambers, transverse websconnecting said slabs at suitable intervals throughout their length, alongitudinal median web extending throughout the length of the elementand united with said slabs, reinforcing elements embedded in said slabs,reinforcing elements embedded in said webs and interlocked with thereinforcing elements of said slabs, and a plurality of strengtheningribs formed upon the inner face of one of said slabs.

7. A concrete building element, comprising a pair of similar slabs,reinforcing elements incorporated in said slabs, means for spacing saidslabs a predetermined distance apart to form dead air chambers, andreinforcing elements incorporated in said spacing means and interlockingwith the reinforcing elements of said slabs for tying the slabs togetherthrou b said spacing means.

8. A concrete bui ding element, comprising a pair of similar slabs,reinforcing ele ments incorporated in said slabs, means for spacing saidslabs a predetermined distance apart to form dead air' chambers, andrein- 4 forcing elements incorporated in said spac ing means andinterlocking with the reinforcing elements of said slabs for tying theslabs together through said spacing means, the reinforcing elements ofsaid slabs extending beyond the ed es of said element and serving asmeans or interlocking engagement with the reinforcing elements ofsimilar slabs arranged in structural association therewith.

9. A concrete building element, compris ing a pair of similar slabs,reinforcing elements embedded in said slabs, s acin and strengtheningwebs connectin sald sla s'together at intervals and provi ed withreinforcing elements interengaging with the reinforcin elements of theslabs, and strengthening ri s formed upon the inner face of one of saidslabs and in line with the reinforcing elements thereof, whereby areinforcing element of the slab lies in juxtaposition to each of saidribs.

In testimony whereof I have hereunto set my hand this 19th day of AugustA. D. 1924.

SIMON LAKE.

